Prefocused head lamp bulb mounting



I p 9, 1952 R. K. BRAUNDORFF I 2,610,290

PREFDCUSED HEAD LAMP BULB MOUNTING Filed Dec. 18. 1948 INVENTOR fizz /mm A. BPAwvs DORFF ATTORNEYS Patented Sept. 9, 1952 Reginald K. Braunsdorff, East Orange, N. J., assigner to Tung-Sol Lamp Works, Inc., Newark,

.N..J., aicorporation of Delaware A plicetionpecemt'eri1s, i sea No.66,009

This invention-relates to electric projector lamps 'as,'forexample,,head lamps for motor vehicles although the invention has other ap- 7 plications. i

"One" object of the invention is a novel and improved electricprojector lamp unit.

A further object of the invention is a novel and improved electricprojector lamp unit of either the singlejor multifil ament' type which is charate1i zedby its simplicity in construction and 4 Claims; (01. 240- 41) assembly, by its efiiciency in projection, bythe precisionmounting of the incandescent lighting source, and'bylow costof manufacture. 1 Ii Further objects of f the invention 'willhereinafterappear; v understanding of jthe invention had to the accompanying drawings iorming, a' part-of this application 'rj e, reference may be h t nv Figsljl to; s are views schematically illustratin theinvention;

Fig." 9 is a sectional view of a reflector element 01' the invention;

Fig. 10 is a schematic sectional View of a lamp unit embodying the'invention;

Fig. 11 illustrates a modification; and ,Fig. 12 isa sectionalview through one end of thelamp bulb.--- i In ;ce'r,tai lamps and particularly of the metallic reflector type; the electric incadescent lamp bulb and the reflector form separate units which are" often sold separately andare required to be assembled V by the manufacturer of the automobiles upon;- whichthe head lamps or projectors are to be mounted orby'other users of the projector lamps. There are a number of disadvantages in this conventional pr'actice,such, for example, as'the necessity of buying two separate units and the assemblythereof, the difllculty of obtaining the exact desired adjustment ofthe lamp bulb in types of conventional projector '20 steps inthe'manufaeture of ala'mp embodying therefiector and the maintenance of such adjustm'ent once it-is made, and other disadvantages. By my invention I have devised a projector. unit in which the disadvantages of the conventional practice-mentioned.- areobViated and which posesses the -advantages,,:amo ng others, of comparatively low cost in manufacture, durable wearmg qualities and permanent precision mounting of the electric light me; one element of the projector lamp or this in vention. 'Thisrefiector is of'metal or any other source in the reflectonl In Fig. "9 I have illustrated a reflector I formend l2 thereof. wire I2 is electrically connected or fastened to v suitable or conventional material. I'havealso illustrated this reflector as approximating a paraboliciorm, but it is understood that themvention is applicable to reflectors not only of "the parabolicform but other'suitable forms as well as, for example, combinations of parabolic andjellipti-cal' shapes and. other suitable' forms' such, for example. as the forms generally used:

in practice. s

jIn 8 I have shown-"an electric incandescent lamp bulb {which forms another elementfof the projector unit of my invention. This embodiment of the incandescentbulb element of the invention comprises a bulb 3 e. lighting fila ment 4 and an'electrieterminalt. The bulb 3- is provided with encore" which isiastenedand. sealed to a metallic disc element 6."This disc 6 hasits inner portion compressed or otherwise processed to form a bulbous part 1 projecting up to a point within the neck 3 of thebulb and.

to form a corresponding recess 8 on the outer portion of the disc. The disc isprovide d on its outer'snrfacewith a multiplicity'oi small bosses 9, in the Particular embodiment shown there be-;

ing three of'these bosses equally and angularly displaced'from each other by 12 0 Also in the particular embodiment shown the disc 6 is provided with a peened over peripheral edge I0 ex:-

tending in the direction of the bulb a, The fila-' ment 4 may be of any suitable shape or'form but generally axially'of thelamp bulb 3 The filament support wire I l is welded or otherwise fastened tothe disc 6, namely to theinner surface of the bulbous part I; the lower end'of the wire being bent as indicated'at H and fastene'd to the disc at a point eccentricallyiof the center l.

thereof. The support wire i2 is sealed atone ,end'intothe bulb-'3 to form anv air andpressure tight joint. For this purpose the portion of the bulb3 opposite the neck 3 is provided with 'a' reduced portion or protuberance 13, the latter being fused in any suitable manner aboutthe support wire l2 at a point adjacent the outer This end l2 of the support the terminal 5' in any suitable manner. In the particular embodiment shownthis terminal 5 is of a thimble jor 'cup-like shape fitting 'over' the" protuberance13 and having its rim 5"'outwardly spun or peened over to fit the rounded portion of the bulb 3 adjoining the protruberance I3. The thimble may be mechanically fastened to the bulb 3 in any suitable manner as, for example, by means of a suitable cement I4. 5 The end of the neck 3' of the bulb is sealed and fastened to the disc Ii in any suitable manner as, for examples by fusing the e-same thereto. 1- The disc. maybe of any suitable materialiasrfor: example, of one of the conventional iron, nickel, chrome alloys on the market to which the glass; of the bulb 3 is readily sealable, by fusing, The metallic filament support wires l I -and-'I2'h1a-y-be-- of nickel or other conventional ,m-aterialiused ,in the making of filament support-wires.v

The reflector I is provided on the interioriandi. axially thereof with a recess 20,. this recess being. formed in any suitable manner out'of themetal' or other material of which the reflector isanade; as by pressing, molding, etc. This recess is defined by; an annular. surface .A disposed, icons. centrically with the. axis D.. of; .the ireflectorr and by;- a :plane -'-.bottom. surfacesB,; disposed,.at right anglesto theaaxis ,C', D...: The..recess-.-sur:

faces :A,and.-B are, formed ;to.-correspond; respeca 25.

tivelyy-with the peripheral; edge III- loigthe discs. 6 and the outer. surface ot thediscrfi on thei'bosses 9 formed thereon. The filament 4-is, precisionm mounted in the bulb 3 so as to bear a predeter-:.-

mined relationship with ,the outer. surface. of: the

disc .6 and the outer surfaceso the peripheral: edge Ill; thereofso; that when the lamp. bulb is; assembled formounting in .the reflector the iila.- ment Willvbear; that-same.-predetermine elae tionship wi-th respecttem the.annularfisuiqfacesvfliia A-and; -B,.-. Accordingly by;therprecision niuntiii of the-filament 14 -inathez-lampbulbjaas described,.... the filament. will cc pmhe desired position .;with relationtoithe focalspointiil ,by the mereeactgofi;

assembling: and fastening. the; lamp bulb inAO the reflector,

Preferably-the dealt-lanes agtig htiortpressed fit within the recess :20.- n thereflectorrfwith, the,..

periphery. I 0-of v thei-diselfirinly iandvitightly engaginget-he annulargsurfac erA andl tlie bossesjeias engaging the plane surface-B I. un t ended means thowever for holding the;flamp bulb. 2 in position e-ven :thoughathei dis c-fldoes-rnotma ella pressed fit inthe; recess. 20.;..1Thi-s ,means come prises ..-a spring. arm. rZIQ hayingl its ,fixedgendk 22 .150 fastened :to theErefiecton. I in' ,any. suitable" man ner. withsthe; other- .end-.of.ithespringiarm ,2 3811:, gaging I the Ithimble "5 .of; the-lamp bulb'z. land; biasing the, lamp .bulb; inthe .directionofiithez 311': row; namely in. the direction tithe iaXisiC; D..'.of.4l55. the reflector. f In. the particular embodiments shownthe spring arm 2| .extend sginwardlwin,a.. direction which is generallyradialwithitheiinner... portion of the-springyarm.-bentiinwardlyttoiform a right angle --portion 23, andthen benti-at: right 60..

angles. to form a 'portionrzLwhichlis lgenenall-y' parallel with the, mainbody portion of thespning arm 2|. Theportion 2dwistpreferablyiin.theform of .a fork iorcollar which straddls-.,or is threafied over the. thimble: .5 and. engaging. the' periphery oa i 5 thereof. the lamp bulb; 2 and Q1: yieldingly;engaged...- by rthemarmk 21;. :toiassistlin holding. the lamp bulb, initslpermanentgoperative relation in the projector-unit.

The. fixed end. 22. nitric-spring arm. 2 I is. rssi, .70

tened Jto..the. reflector. element .1 in .a -manner. 120..., have the arm 21. electrically insulated therefrom so -.thatIv this arm 2 I. functionsmalso has .anielec tri'cal connection for .thei.lamp-.;, bulb L2 -with-\ the.

other. I connection... being; .providedibetweenj-...the.. .75.

2,610,290 "j f j "automobile or other place of use since such mounting forms no part of the present invention? I have illustrated in dotted lines at 26 a -suitable-cover nrg-lens for the lamp and the dertai-lsiof-ithis icove or lens and its mounting are omitted:::fr-om:th drawings for convenience in illustration sinceithey form no part of the present invention."

The-parts of the lamp bulb 2 may be assembled and mounted in any suitable manner. In Figs...1 .to.,8 I have illustrated .sohem-atically..cer-.- tain of. the; steps .which m'aybeiiollolwed .in such; assembly}andjmounting; Fig 1 .illustratesrthe disc 6 'which has been preformed in any suitable manner. It is provided with, an exhaust. opening 2 1 f the latter. .inithe. tparticularsembodimenti1 shown .being io'rmediin .-thei: bulbous,-..par.tl;1 and centrally thereof. In 'Fi-g..,l2 the ,filamehtimountu. support .wire I I i-slillustrated-as;havi11g..beensuita ably; fastenedaras lbw-welding thegsupportgwire having. been bent. as indicated atv I I! to. collarithe. exhaust I openingLZ 13. The im-ountinglof vthe -fila-.. ment 4 with one end fastened tothe. supportiwire I I is shownin Fig-.l.3. -and.in; Figl tithe; other;sup

4r port wire I2 is illustrated ashaving the lower 'end 4.... in; Fi .5 the disc and 'thffilamnth1cnhtfare illustrated-as having.beenlassemblediin theibulbz 3 with the peripheral edge of the endofgthe neck; 3i -having been fused; and sealed toitheldisc in .any. suitableon conventional-lmanner this' seal, being indicated at 30. Either beforersimultanei-g ouslywith or after the effectingpi {the seal 3'q.-the

support Wire I2 is sealed to" the bulb ginby the melting: and. timing of the outer-lend of the protuberance I3 to the,supportawireljz at' aipoifnt adjacent its projectingaends. 12L. 6-91 have illustrated the rattachment: ot. a suitablegex haust tube 31' to the under side ottherbulbousu part I of-.- thedisc; This. exhausttube-a Itmay be ot-glassor any, othen.suitablem'aterialiwhich may; be sealed tothe metallic-,disclifi In theparticue lardernbodi nient shown I, have illustrated theiexa hauststubeTS I :as being of glass. Alter. thefusing I and vseal-ing bf thesupport Wire I Ltothbulb 3 the: thimbl-e 5 ism thenfastenedetorthez plrotuber. annex-I 3; of the bulb as .shown .inrFig fl In- Fig; '8 I have illustrated-the"exhaustztube 3i asihay-ine b-een severed-,fromsthe disc .1 laiter-the-lexhaust andz-zpressingof; the-bulb. 3,Vleaying ar'sealed iportionatllwo-fethe exhaustn-tube..thereotto form as permanentpart ofthelampg niti The-l mp bulb.- is sealedroifz :atva :point: so as to: have the-pqrtiomz 3 I--':- ofzthe: exhaust :tubez: remainingseomnletely within the recess 8 formed by the bulbous parts-.1 1.1" The. danger f:ibreakingstheztexhmistiportion 3 I during assembly with the irefiector eIenx ent: -i cr me projector;unit" is thereby mininiizedif In Figs: 1 to"10 I have illustrated -a single ma:- mentlampwhile 'in*Eigsi -ll and'12- I haveishown a multi fil'ament 'lampz Hdwevenf single-"i and multi filament' :projector lamps' are QWBII and it'isto be understood thatth invention uses.. not; concern. .theifnumber offilampflfilamentslibut}.

' as shown in section in rather a lamp structure embodying one or more filaments. I

The filaments in the lamp shown in Figs. and 11 are denoted by the numerals 36 and 31. A single ground wire 38 is provided for both filaments 3-5 and 31 this ground wire 38 being fastened to the disc 6 as described above with respect to the first embodiment. This ground support wire 38 is provided at its end with a bent portion 38 and the filaments 36 and 31 are fastened and electrically connected at one end with this portion 38' of the ground support wire. The filaments 36 and 31 are provided with individual support wires 39 and 40 respectively which extend upwardly and are separately and individually sealed into the protuberance l3 of the bulb 3 Fig. 12. In this embodiment a sleeve 35 is fastened to the protuberance l3'in any suitable manner as by the cement 4| illustrated. These support wires 39 and 40 extend through the insulating cement 4| and. are electrically connected with a pair of terminals '39 and 40', respectively, these terminals bein mounted in an insulating disc 42. In this embodiment the lamp bulb may be held in its operative position in the reflector element as described with respect to the embodiment of Figs. 1 to 10 and suitable terminals purposely omitted from the drawings since they form no part of the invention may be made from the terminals 39 and 40' to the circuit or circuits controlling them, whereby either of the filaments 36 and 31 or both may be connected in circuit.

I claim:

1. In an electric headlamp, a metallic reflector having an axial recess formed at the rear and on the interior thereof and an electric incandescent filament lamp having the bulb thereof sealed to a closing plate member conforming to and mounted in said recess and at least one filament in the lamp bulb mounted in predetermined relation with respect to the periphery and the bottom of the plate member so as to have the filament accurately mounted at a predetermined point with respect to the focus of the reflector and spring holding means engaging the opposite end of the bulb and biasing it inwardly and holding the same in fixed position, said spring biasing and holding means forming electrical connecting means for energizing the lamp and the reflector forming a ground connection for the lamp.

2. In an electric headlamp, a reflector having an axial recess formed at the rear and on the interior thereof and an electric incandescent filament lamp having the bulb thereof sealed to a closing plate conforming to and mounted in said recess and at least one filament in the lamp bulb mounted in predetermined relation with respect to the periphery and the bottom of the plate member so as to have the filament accurately mounted at a predetermined point with respect to the focus of the reflector and spring holding means engaging the oppositeend of the bulb and biasing it inwardly and holding the same in fixed position, said spring biasing and holding means being carried by the reflector and comprising a spring arm extending radially inward and having a fork engaging an electrical contact carried on the opposite end of the lamp bulb.

3. In an electric headlamp, a reflector having an axial recess formed rearwardly and on the inner surface thereof and an electric filament lamp bulb being sealed at one end to a metallic plate conforming to and mounted in said recess, at least one filament in the lamp precision mounted with respect to said plate and said bulb having a reduced outer end having a metallic sleeve thereon and functioning as a contact for the filament, and a metallic spring arm mounted at one end on the interior of the reflector near the periphery thereof and having its other end engaging said sleeve and biasing the lamp into its operative position.

4. In an electric headlamp, a reflector having an axial recess formed rearwardly and on the inner surface thereof and an electric filament lamp bulb being sealed at one end to a metallic plate conforming to and mounted in said recess, at least one filament in the lamp precision mounted with respect to said plate, spring-biasing and holding means engaging the opposite end of the bulb for holding the same in fixed position,

and electrical contact means on said opposite end of the bulb serving as terminal means for the lamp, the reflector forming a ground connection for the lamp.

REGINALD K. BRAUNSDORFF.

REFERENCES CITED The following references are of record in the 

